Page 2 - iQ; Specifications subject to change without notice.
Page ii iQ Series , Auto User’s Manual Dukane Manual Part No. 403-573-02 Printed in the United States of America. Part Number: 403–573–02 This ultrasonic equipment is manufactured under one or more of the following U.S. Patents:3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 5,880,580 6,984,921...
Page 3 - Revision History; Revision
Page iii Dukane Manual Part No. 403-573-02 Revision History Revision Revision Number Summary Date - 00 Original release. 10/09/2007 - 01 20kHz and 30kHz models added. 08/27/2009 System I/O Connector signals modified. Amplitude control added. - 02 I/O Connector Pin 9 signal scale revised. 12/15/2010...
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Page 5 - Contents; Standard; Section 5 - Specifications
Page v Dukane Manual Part No. 403-573-02 Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1 General User Information . . . . . . . . . . . . . . . 3 Generator Overview . . . . . . . . . . . . . . . . . . . 4 Key Generator Features . . . . . . . . . . . . . . . . 4 Ther...
Page 7 - SECTION 1; Introduction
Page Section 1 – Introduction Dukane Manual Part No. 403-573-02 SECTION 1 Introduction General User Information . . . . . . . . . . . . . . . . . . 3 Read The Manual First . . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . 3 Drawings and T...
Page 9 - General User Information; Read This Manual First; CAUTION; C a u t i o n s t a t e m e n t s; WARNING; NOTE
Page 3 Section 1 – Introduction Dukane Manual Part No. 403-573-02 General User Information Read This Manual First Before operating your ultrasonic generator, read this User’s Manual to become familiar with the equipment. This will ensure correct and safe operation. The manual is organized to allow ...
Page 10 - Generator Overview
Page 4 iQ Series , Auto User’s Manual Dukane Manual Part No. 403-573-02 Generator Overview This generator is designed for ultrasonic applications con-trolled by a Programmable Logic Controller (PLC). Us-ing the available system control inputs and outputs, the generator can easily be integrated in...
Page 11 - Thermal Considerations
Page 5 Section 2 – Health & Safety Dukane Manual Part No. 403-573-02 Thermal Considerations The thermal design of this generator is for applications that require 600 watts or less of power at less than a 50% duty cycle. For applications that require higher duty cycles, an optional cooling packa...
Page 13 - SECTION 2; Health and Safety
Page 7 Section 2 – Health & Safety Dukane Manual Part No. 403-573-02 SECTION 2 Health and Safety General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical Safety . . . ....
Page 15 - General Considerations; Plastics Health Notice; deflectors may be installed
Page Section 2 – Health & Safety Dukane Manual Part No. 403-573-02 General Considerations Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your equipment. In this manual, the term system refers to a complete group of components associated ...
Page 16 - Electrical Safety; Power Grounding Connection; avoid the risk of fire, electrical
Page 0 iQ Series , Auto User’s Manual Dukane Manual Part No. 403-573-02 Electrical Safety Power Grounding Connection Figure 2-1 illustrates how the AC line is connected. Figure 2–1 AC Line Connection CAUTION I f t h e r e i s a n y q u e s t i o n a b o u t g r o u n d i n g o f y o u r ...
Page 17 - How to Lift Safely; Ta k e c a r e i n l i f t i n g t h e
Page Section 2 – Health & Safety Dukane Manual Part No. 403-573-02 Step 1. Stand close to the load with your feet spread apart about shoulder width, with one foot slightly in front of the other for balance. Step 2. Squat down bending at the knees (not your waist). Tuck your chin while keeping y...
Page 19 - SECTION 3; Installation; Standard Model Configuration
Page 3 Section 3 – Installation Dukane Manual Part No. 403-573-02 SECTION 3 Installation Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power Grounding . . . . . . ...
Page 21 - Unpacking
Page 5 Section 3 – Installation Dukane Manual Part No. 403-573-02 Unpacking Carefully open your shipping container, and make sure it contains the items shown on the shipping documents. Inspect all items, and report any missing items or damage immediately. Placing Make certain generator placement an...
Page 22 - Power Grounding; Chassis Grounding Stud; shown. Use a STAR configu
Page iQ Series , Auto User’s Manual Dukane Manual Part No. 403-573-02 Power Grounding For safety, the iQ Auto chassis must be properly ground- ed. The power line ground connection is located on the center screw terminal on the AC Power Inlet pluggable screw terminal connector.Thi...
Page 23 - AC Power Inlet; Connecting Cables
Page 7 Section 3 – Installation Dukane Manual Part No. 403-573-02 Connecting Cables Standard Model Configuration Complete three basic connections for the standard con- figuration as shown below: • AC Line Input • System Control Inputs/Status Outputs • Ultrasound Output • Grounding Details about the...
Page 24 - System I/O Connector Pinout
Page iQ Series , Auto User’s Manual Dukane Manual Part No. 403-573-02 Pin Signal Name 1 Enable Out (+22V Current Limited) 2 Enable In (Jumper to Pin1, without an E-Stop switch) 3 Overload Out (system overload status output) 4 U/S Status Out 5 Any Fault Out 6 Power OK Out 7 Output...
Page 26 - Optional MPC Interface Connections; Amplitude adjustment will affect; ALL
Page 20 iQ Series , Auto User’s Manual Dukane Manual Part No. 403-573-02 Optional MPC Interface Connections Complete the same basic connections used for the stan-dard iQ Auto configuration as previously described. • AC Line Input • System Control Inputs/Status Outputs • Ultrasound...
Page 27 - MPC I/O Connector Pinout
Page 2 Section 3 – Installation Dukane Manual Part No. 403-573-02 Pin Signal Name 1 Setup Bit 0 Input 2 Setup Bit 1 Input 3 Setup Bit 2 Input 4 Setup Bit 3 Input 5 Input Common 6 MPC Ready Out 7 Output Common Table 3-II MPC I/O Connector Signals MPC I/O Connector Pinout The MPC I/O connector is a t...
Page 28 - Ultrasound Output Connector; MPC Probe Control
Page 22 iQ Series , Auto User’s Manual Dukane Manual Part No. 403-573-02 NOTE Ultrasound Output Connector The ultrasound output connector used with all standard generators is a high voltage (5000V) coaxial style SHV-BNC connector. This connector provides superior shielding of elec...
Page 29 - MPC Module Installation; Cut Outs
Page 23 Section 3 – Installation Dukane Manual Part No. 403-573-02 MPC Module Installation Guide MPC modules are designed for assembly systems where one ultrasonic generator is sequenced to as many as 16 ultrasonic probes.The MPC module is typically supplied as a stand-alone bench-top unit, or as a...
Page 30 - Rear Connections; Front Connections
Page 24 iQ Series , Auto User’s Manual Dukane Manual Part No. 403-573-02 Connecting Cables For stand-alone modules and securely installed panel mounted modules: Rear Connections Refer to Figure 3-4 below. Complete these connections.1. Earth ground - Connect one end of a user-suppl...
Page 31 - MPC Module Status LEDs; System Status; Probe Selection Status; lights up; turns to
Page 25 Section 3 – Installation Dukane Manual Part No. 403-573-02 MPC Module Status LEDs System Status The front panel SYSTEM STATUS LED lights up GREEN when the system is powered and ready - E in Figure 3-6. If this LED is lit with a YELLOW/ORANGE color, a recoverable fault condition has tripped....
Page 33 - SECTION 4; System Operation
Page 27 Page 2 iQ Series , Auto User’s Manual Section 4 –System Operation Page 27 Page 2 iQ Series , Auto User’s Manual Section 4 –System Operation Dukane Manual Part No. 403-573-02 SECTION 4 System Operation Standard iQ Auto System Operational Test . . . ...
Page 35 - Troubleshooting Abnormal; Auto System; Ultrasound Activation Connections; Continued
Page 2 Page 2 iQ Series , Auto User’s Manual Section 4 –System Operation Page 2 Page 2 iQ Series , Auto User’s Manual Section 4 –System Operation Dukane Manual Part No. 403-573-02 Standard iQ Auto System Operational Test Step 1. Verify that the standard sy...
Page 36 - Auto System with MPC; tem Conditions; MPC Module; is
Page 3 Page 30 iQ Series , Auto User’s Manual Section 4 –System Operation Dukane Manual Part No. 403-573-02 Page 3 Page 30 iQ Series , Auto User’s Manual Section 4 –System Operation Five fault conditions are monitored by the iQ Auto system for Any Fault: •...
Page 37 - Fault Status; output signals; Continued from previoius page
Page 3 Page 30 iQ Series , Auto User’s Manual Section 4 –System Operation Page 3 Page 30 iQ Series , Auto User’s Manual Section 4 –System Operation Dukane Manual Part No. 403-573-02 Options for U/S Activation Connections : • Optionally monitor the U/S Acti...
Page 39 - SECTION 5
Page 33 Section 5 – Specifications Dukane Manual Part No. 403-573-02 SECTION 5 Specifications Generator Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . 35-36 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Operating Environment. . . . ....
Page 43 - Operating Environment; Weight
Page 37 Section 5 – Specifications Dukane Manual Part No. 403-573-02 Operating Environment Operate the generator within these guidelines: Temperature : 40°F to 100°F (+5°C to +38°C) Air Particulates : Keep the equipment dry. Minimize exposure to moisture, dust, dirt, smoke and mold. Humidity : 5% t...
Page 45 - FCC; fications to the generator; Rating
Page 3 Section 5 – Specifications Dukane Manual Part No. 403-573-02 FCC The generator complies with the following Federal Communications Commission regulations. • The limits for FCC measurement procedure MP-5, “Methods of Measurement of Radio Noise Emissions from ISM Equipment”, pursuant to FCC Tit...
Page 47 - SECTION 6
Section 6 – Automation Interface Page 4 Dukane Manual Part No. 403-573-02 SECTION 6 Automation Interface Input/Output Connection Examples . . . . . . . . . . . . . . . . . . . 43 PNP (Sourcing) Type Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . 43 NPN (Sinking) Type Input Circuit . ...
Page 49 - iQ Auto
Section 6 – Automation Interface Page 43 Dukane Manual Part No. 403-573-02 iQ Auto (same as above) Input Common U/S Activate Fault Reset Ground +DC Input Voltage Range DC 24V 10% Input Current 10mA(typ) @ DC 24V input PNP (Sourcing) Type Input Circuit (Pin 13) (Pin 12) (Pin 11) System I/O Connector...
Page 51 - Overload; Any Fault
Section 6 – Automation Interface Page 45 Dukane Manual Part No. 403-573-02 (same as above) Overload U/S Status Ground +DC NPN Type Output Circuit Rated Output Voltage DC 24V 10% Maximum Output Current 500mA/1 Output Output Driver N Channel Power MOSFET Gate Drive L L (same as above) (same as above)...
Page 52 - Dedicated E-Stop Switch Wiring Diagram
Page 4 iQ Series , Auto User’s Manual Dukane Manual Part No. 403-573-02 Figure 6-4 E-Stop Circuitry iQ Auto Enable Out Enable In Dedicated E-Stop Switch Wiring Diagram System I/O Connector (Pin 1) (Pin 2) User suppliedE-stop switch iQ Auto Enable Out Enable In Automation System ...
Page 53 - SECTION 7
Section 7 – Contacting Dukane Page 47 Dukane Manual Part No. 403-573-02 SECTION 7 Contacting Dukane
Page 55 - Contacting Dukane; Identify Equipment; Mailing Address; Website
Section 7 – Contacting Dukane Page 4 Dukane Manual Part No. 403-573-02 Contacting Dukane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • Model number, line voltage and serial number. • Fault status. • Problem description an...
Page 57 - Dukane ISO; ISO CERTIFICATION; System Infrastructure.; C E R T I F I E D
Dukane ISO ISO CERTIFICATION Dukane chose to become ISO 9001:2008 certi-fied in order to demonstrate to our customers our continuing commitment to being a quality vendor. By passing its audit, Dukane can assure you that we have in place a well–defined and systematic approach to quality design, manu-...
Page 58 - iQ Series; Ultrasonic Generator/Power Supply; Please refer to our website at:
Part No. 403-573-02 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949 iQ Series , Ultrasonic Generator/Power Supply Auto User's Manual Printed in the United States of America www.dukane.com/us Please refer to our w...
